Assembly method for spinal cord stimulation lead

Abstract

Methods for manufacturing a medical electrical lead for spinal cord stimulation include coupling distal portions of each of a pair of lead bodies to one another. The distal portions each include a plurality of electrode surfaces coupled thereto. Each of the distal portions may further include a column of conductive rings coupled thereto, wherein each electrode surface of the first and second portions is coupled to a corresponding conductive ring of the first and second portions, respectively.

1. A method for manufacturing a medical electrical lead for spinal cord stimulation, the method comprising:
 coupling each of a first plurality of electrodes to a corresponding conductive ring of a first column of conductive rings coupled to a distal portion of a first elongate lead body, each of the first plurality of electrodes including an approximately planar electrode surface; 
 coupling each of a second plurality of electrodes to a corresponding conductive ring of a column of conductive rings coupled to a distal portion of a second elongate lead body, each of the second plurality of electrodes including an approximately planar electrode surface; 
 coupling the distal portion of the first elongate lead body to the distal portion of the second elongate lead body so that the electrode surfaces of the first plurality of electrodes are angled toward the electrode surfaces of the second plurality of electrodes such that a plane extending along, and orthogonally out from, the electrode surfaces of the first plurality intersects a plane extending along, and orthogonally out from, the electrode surfaces of the second plurality. 
 
     
     
       2. The method of  claim 1 , wherein each of the first plurality of electrodes is coupled to the corresponding conductive ring of the first column such that the electrode surface of each of the first plurality extends laterally out from the distal portion of the first lead body. 
     
     
       3. The method of  claim 2 , wherein each of the second plurality of electrodes is coupled to the corresponding conductive ring of the second column such that the electrodes surface of each of the second plurality extends laterally out from the distal portion of the second lead body. 
     
     
       4. The method of  claim 1 , further comprising placing the distal portions of the first and second lead bodies side-by-side approximately parallel to one another and spaced apart from one another for coupling together. 
     
     
       5. The method of  claim 1 , further comprising placing the distal portions of the first and second lead bodies side-by-side approximately parallel to one another for coupling together, wherein each electrode of the first plurality is longitudinally aligned with a corresponding electrode surface of the second plurality. 
     
     
       6. The method of  claim 1 , wherein the coupling of the distal portions of the first and second lead bodies is accomplished by a molding process. 
     
     
       7. The method of  claim 1 , wherein coupling the distal portion of the first elongate lead body to the distal portion of the second elongate lead body comprises:
 placing the distal portions into a mold alongside one another; 
 injecting a polymeric material into the mold to form to form a paddle-like member for coupling the distal portion of the first lead body to the distal portion of the second lead body, the paddle-like member including a first side, along which a surface of each of the electrodes of both the first and second pluralities are to be exposed, and a second side for enclosing the distal portions of the first and second lead bodies. 
 
     
     
       8. The method of  claim 7 , further comprising placing a mesh over the distal portions of the first and second lead bodies in the mold. 
     
     
       9. The method of  claim 7 , wherein the first side of the paddle-like member includes a concave surface to extend between the electrode surfaces of the first and second pluralities. 
     
     
       10. The method of  claim 7 , wherein the second side of the paddle-like member includes a flat portion. 
     
     
       11. A method for manufacturing a medical electrical lead for spinal cord stimulation, the method comprising:
 coupling each of a first plurality of electrodes to a corresponding conductive ring of a first column of conductive rings coupled to a distal portion of a first elongate lead body; 
 coupling each of a second plurality of electrodes to a corresponding conductive ring of a column of conductive rings coupled to a distal portion of a second elongate lead body; and 
 coupling the distal portion of the first elongate lead body to the distal portion of the second elongate lead body so that each electrode surface of the first plurality of electrodes is longitudinally aligned with a corresponding electrode surface of the second plurality of electrodes. 
 
     
     
       12. The method of  claim 11 , wherein each of the first plurality of electrodes is coupled to the corresponding conductive ring of the first column such that the electrode surface of each of the first plurality extends laterally out from the distal portion of the first lead body. 
     
     
       13. The method of  claim 12 , wherein each of the second plurality of electrodes is coupled to the corresponding conductive ring of the second column such that the electrodes surface of each of the second plurality extends laterally out from the distal portion of the second lead body. 
     
     
       14. The method of  claim 11 , wherein each electrode surface of the first and second pluralities of electrodes is approximately planar. 
     
     
       15. The method of  claim 11 , wherein coupling the distal portion of the first elongate lead body to the distal portion of the second elongate lead body comprises:
 placing the distal portions into a mold alongside one another; 
 injecting a polymeric material into the mold to form to form a paddle-like member for coupling the distal portion of the first lead body to the distal portion of the second lead body, the paddle-like member including a first side, along which a surface of each of the electrodes of both the first and second pluralities are to be exposed, and a second side for enclosing the distal portions of the first and second lead bodies. 
 
     
     
       16. The method of  claim 15 , wherein the first side of the paddle-like member includes a concave surface to extend between the electrode surfaces of the first and second pluralities. 
     
     
       17. The method of  claim 15 , wherein the second side of the paddle-like member includes a flat portion.